Assembly

1. Assemble sleeve and hub assembly for 3rd-4th and, 5th and high-low synchronizing.

NOTE: Position open ends of spring 120° apart.

2. Install 3rd drive gear, baulk ring, and sleeve and hub assembly for 3rd-4th needle bearing (32 x 36 x 25.7) on transmission main shaft.

NOTE: Align groove in baulk ring with shifting insert.





3. . Install 4th needle bearing race (1) onto transmission main shaft using Special Tool (ST1), ST2 and a press.
ST1 899714110 Remover, or equivalent
ST2 499877000 Race 4-5 Installer, or equivalent





4. Install baulk ring, needle bearing (32 x 30 x 25.7), 4th drive gear and 4th gear thrust washer to transmission main shaft.

NOTE: Face thrust washer in the correct direction.





5. Drive ball bearing (1) onto the rear section of transmission main shaft using ST1, ST2 and a press.
ST1 899714110 Remover, or equivalent
ST2 499877000 Race 4-5 Installer, or equivalent





6. Using the same tools as in step 5 above, install the following parts onto the rear section of transmission main shaft.
- 5th gear thrust washer

NOTE: Face thrust washer in the correct direction.

ST1 899714110 Remover, or equivalent
ST2 499877000 Race 4-5 Installer, or equivalent
- 5th needle bearing race





7. Install the following parts to the rear section of transmission main shaft.
- Needle bearing (32 x 36 x 25.7)
- 5th drive gear
- Baulk ring
- Sleeve (A) and hub assembly
- Insert stopper plate (B)
- Lock washer (C) (22 x 38 x 2)
- Tighten lock nuts (D) (22 x 13) to the specified torque using ST1 and ST2.

ST1 499987003 SOCKET WRENCH (35)
ST2 498937000 TRANSMISSION HOLDER

NOTE:
- Align groove (E) in baulk ring with shifting insert.
- Be sure to fit pawl (F) of insert stopper plate into 4 mm (0.16 inch) diameter hole in the boss section of synchronizer hub.
- Secure lock nuts in two places after tightening.